Zig Electronics X-3 Instruction Manual

THE ZIG X-3

CHARGER AND POWER

SUPPLY

UNIT

INSTRUCTIONS FOR FITTING

AND

USE

INSTRUCTIONS FOR USE AND FITTING

Piease read the following instructions carefully before installing or operating the
X-3 charger and power supply unit.

INTRODUCTION

The X-3 is a fully automatic battery charger, connected to a six cell lead acid battery

with a nominal voltage of 13.8 volts, the unit will charge and recharge the battery by

raising the terminal voltage to equal that of the output of the battery charger. As the
battery voltage increases the input current from the battery charger automatically
reduces until it ceases to flow, this provides fast and efficient battery charging and

eliminates the possibility of overcharging, unless the battery is at fault.

LOCATION

Choose a suitable location for the X-3 bearing in mind the following:­a.

Minimum size of compartment must be 450 x300 x250mm this will allow cool

air to circulate around the unit, necessary for correct operation.

b. Ventilation preferably to the outside of the van in the form of at least 2 x 25mm

diameter vented holes must be provided.

N.B. All transformer operated appliances generate heat and therefore run hot when

operating at full capacity.
c. Access to the battery compartment and mains inlet distribution system will

be required.

d.

The unit may be fitted horizontally or vertically and must be securely fixed to

prevent movement whilst the vehicle is in motion.

N.B. If the unit is mounted vertically the connection terminals must be situated a*

the bottom.

WARNING

The charger is fitted with a safety device which provides a time delay :-
approximately 2 seconds to reduce the surge of inrush current when switchec : -

For this device to function correctly there must be an interval of 45 secc"

=

between switching off and on.

The green indicator light will illuminate when the charger is working.

NOTE

Check appliance before installation, if the supply cord is damaged it must
replaced by a repair shop approved by the manufacturer as specialist ::: = =-=
required.

2

INSTALLATION X-3

1.

The X-3 must be mounted to a secure surface using 4 x No.8 x 11/4

woodscrews or similar through the 5mm diameter holes in the feet of the
charger, to give a minimum clearance of at least 25mm all round.

INSTALLING THE BATTERY

If a space has not been allocated for the battery during manufacture the following
must be observed before installation.

1.

The interior of the battery compartment must be protected against corrosive

effects of acid-laden gases that may be released from a battery when it is on
charge.

2.

The compartment must be ventilated at low and high level to the outside of

the van. If it is accessible from the outside it must be sealed from the inside
structure.

3. The battery must be secured upright where it cannot tip over-it must be free
from movement when the vehicle is in motion.

The X-3 is designed to charge 12V lead acid type batteries, the capacity of the
battery must not be less than 60 ampere hour. (The bigger the battery the better).
Should the battery contain a faulty cell the terminal voltage will not rise sufficiently
to switch the charger off and the battery will eventually boil dry, the most common
cause for cell failure is discharging the battery below the recommended level,
approximately 10V.

WIRING

Using cable of at least 2.5mm sq. (50/0.25), each wire when fitted should have
identification numbers, letters, or colour codes.

Connections are made to the X-3 using 1/4" fast on insulated crimp type connectors.
Please refer to suggested wiring diagram on page 6.

AUXILIARY BATTERY CONNECTIONS

Terminal 1 on the X-3 to positive terminal on the auxiliary battery (via 25 amp in-line

fuse supplied).

Terminal 4 on the X-3 to negative terminal on the auxiliary battery.

12S CONNECTIONS

Terminal 2 on the X-3 to pin 2 on the 12S plug
Terminal 3 on the X-3 to pin 3 on the 12S

plug.

CONTROL PANEL CONNECTIONS

Terminal 1 on the X-3 to auxiliary battery connection on the control/distribution

panel.
Terminal 4 on the X-3 to negative on the control panel.
Terminal 5 on the X-3 to power remote charger "ON" indicator (if utilized).

3

MAINS

ELECTRIC

240V WIRING

The

X-3 does not control the mains facilities within your van

- it

uses mains 240 volts

during

its

operation:-

WARNING

Mains

electricity

can

be

dangerous particularly

in

mobile installations such

as

caravans and yachts.

If

you

do

not

have the necessary knowledge you should

not

attempt the following installation you should entrust

it

to a qualified electrician. The

installation must

be in

accordance with

the

relevant

IEE

wiring regulations.

A

residual Current Circuit Breaker (RCCB)

or

Earth Leakage Circuit Breaker

(ELCB)

must

be

fitted. This

is an

inexpensive

way

of

protecting against electric

shocks.

The

device fitted must

be of

current operated type

of

the

following
specification:
25

amp

30

milliamp operating

in

approximately

30

milliseconds.

When

all the

necessary

12

volt connections have been made the mains wiring

can

be completed. The mains input

plug

and socket must

be

polarised (connection can

only

be

made one way round). Should

you

find yourself

in a

situation where

the

polarity

is

reversed, possibly

on

the

continent

the

operation

of

the Zig

unit will

continue

as

normal however steps must

be

taken

to

rectify the situation

as

soon

as

possible

as

other electrical devices may

be a source

of

shock.

We

recommend

you

carry a polarity tester when travelling abroad.

The

plugs and sockets are widely available from caravan dealers and chandlers and

must

be to

BS4343. Different types

may

be

required abroad

if in

doubt your site

operator will

be

able

to

help.

The

socket chosen may

be

flush

or

surface mounted, and should

be

situated

as

near

to

the

RCCB

as

possible

and

should

be

connected using 2.5mm

sq

cable

not

exceeding 2 metres

in

length. The input

cable

for

the X-3

may now

be

connected

preferably

via a covered junction

box as

follows:

BROWN

to

LIVE

(marked

L or

red

in

colour)

BLUE

to

NEUTRAL (marked

N or

black

in

colour)

GREEN/YELLOW

to

EARTH

(marked

E or

green

in

colour)

Input 198-240 volts A.C. 50/60HZ

WARNING:

This appliance must

be

earthed.

We

strongly recommend the X-3

is

built into the van permanently, the use

of

plug

and socket connections

is

not

advised.

If a 13

amp

plug

is

used this must

be

connected

as

follows:

The
letter

GREEN & YELLOW
BLUE
BROWN

to

earth

-

to

neutral

to

live

The

colours

of

the

wires

in

the

mains lead

may not

correspond with

the

coloured

markings identifying

the

terminals

in

the

plug,

if

so

proceed

as

follows:

The

wire that

is

coloured green and yellow must

be

connected

to

the terminal

in

the

plug

marked with

the

letter

E or

the earth symbol.

±

The
the

Secure
no

Once
qualified

The
supply
size

3.

4

The wire which is coloured blue must be connected to the terminal marked with the
letter N or coloured black.

The wire which is coloured brown must be connected to the terminal marked with
the letter L or coloured red.

Secure all mains connections with cable clips and check the installation ensuring
no strands of wire are astray which may short to earth.

Do not connect the mains supply at this stage.
Once the complete electrical installation has been satisfactorily checked by a

qualified electrican the X-3 can be tested.
The mains power to your caravan should be obtained from a normal domestic

supply via a fixed connection point. The hook-up cable should have a conductor
size of at least 2.5mm sq. and when connected should be uncoiled.

In order to ensure the unit is functioning correctly note the following procedure:-

1.

Disconnect auxiliary battery by removing the in-line fuse.

2.

Hook the caravan to the mains supply.

3. Switch the X-3 power supply on.

4.

If the 12 volt accessories work in the van the unit is functioning correctly.

5. Replace in-line fuse.
The unit is unaffected by low input voltages or reversed polarity in the incoming

supply (see specification) ensuring that it works to its full potential particularly
when travelling abroad.

WIRING THE TOWCAR

Pin 4 - (green, vehicle positive supply)
Pin 3 - (white, negative)
Pin 2 - (blue, split charging)
Pin 6 - (red, refrigerator supply).

N.B. Under no circumstances must any of the above circuits be interconnected.

The above is provided for your information only, please note the split charge facility

available from the car is automatic and is totally independent from the X-3.

REVERSED BATTERY CONNECTION

The X-3 supply unit is fully protected against reversed battery connection. Should
this happen it will be necessary to reconnect the battery leads the correct way

round and also replace the 25 ampere inline fuse.
N.B. If a battery is not used or is heavily discharged the load drawn by the

accessories must not exceed the rated output of the X-3.
Your Zig charger is designed to give years of trouble free service it is rigorously

tested and complies with the following standards:-

BS 6765
BS.

EN. 60335-2-29 : 1991.
NCC/SMMT Regulations
RFI : FCC 20780 level B

VDE 0871 level A

And their European Norms where applicable.

5

PRODUCT SPECIFICATION - X-3 POWER SUPPLY

Input Specification:

1.

Rated input voltage

2.

Rated input current

198-240 VAC

0.8A(RMS) max at 230 VAC

3. Rated input frequency:

47 Hz-63 Hz.

Output Specification

1.

Rated output voltage: Nominal 13.8V

2.

Rated output current (continuous)

OA - 6.5A

3. Ripple and Noise: 100 mv p-p

4.

Output voltage, stability:

+/- 0.5%

5. Maximum power: 139 watts

6. Maximum current: 10A

RCCD

TRIP

i

5 amp

<

10 amp

to ign.

car

battery

ISA

' 1

25A

RM 14

o

CONNECTION

X-3

12 3 4

IT'T'T'T1

CONTROL PANEL

+ aux
+ car

—negative

This = — m wm
una..:-:

Fuses i~z -jmgai

What::

1.

•I'j- M

2. C:-JC-*»

3. If

CARAVAN
BATTERY

SUGGESTED WIRING

DIAGRAM X-3

This G^ar

6

GUARANTEE

Thankyou for purchasing a ZIG product.

Peter Everard Ltd., and its subsidiary Zig Electronics Ltd., Guarantee this product against
failure due to faulty workmanship and/or material for a period of 12 months from the date of
original purchase.

This Guarantee will be extended when the product is fitted to a caravan or motor-caravan by an
original equipment manufacturer, the term will then be 12 months from the date that the
caravan first became the subject of a retail sale.

It shall be at the company's discretion to determine the method of rectifying the fault.
This Guarantee is not transferable and any claims made under the Guarantee MUST be made

to the supplier from whom the product was purchased; (or to the dealer who supplied the
caravan originally). It is important that proof of the date of purchase is supplied by the
customer.

In the event of a claim under this Guarantee please do one of the following things:

1.

Return the product or the caravan to the original supplier together with proof of the date

of purchase.

2.

Contact the dealer for information about repairs in

situ.

N.B. There are no user serviceable parts within the X-3.

IMPORTANT

This guarantee will be invalidated if any attempt has been made to open, modify or repair by
unauthorised personnel.

Fuses and fuseholders are not covered for failure or damage by whatever cause.

What to do if a problem occurs outside the Guarantee period:

1.

Ask your local caravan dealer if he can service the unit for you.

2.

Contact a qualified electrician (or if the problem is confined to the 12 volt circuits), a

qualified auto-electrician.

3. If 1 and 2 above are unsuccessful, you may return the product to the manufacturers:
Peter Everard Ltd., at Cashes Green, Stroud, Glos. GL5 4RA subject to the
following:

(a) The product is packaged in accordance with Post Office requirements, e. a

minimum of 2" (50mm) of packing material around the parcel. Peter Everard Ltd.,

will not be responsible for any damage in transit.
(b) A letter describing full details of the fault, including how and when : cc:_"e:
(c) A cheque for £23.50

(incl.

vat) made payable to Peter Evera-- _:ci ~- s = ::
defray charges for checking and return postage. If any repa -s -ec_ rez e> zaz
this figure you will be advised in writing before repsi'scon-n-e-ce . : .z-
decide not to proceed the above amount wiil ce

r5".-roen'

:z yc- ess ".~e zzs: :z

return postage.

This Guarantee does not in any way affect your statutory rights

7

WARNING:

This document is copyright, it may not be reproduced
in any form, copied, or in any way retrieved for any purpose
whatsoever except with the written consent of the publishers. The
manufacturers reserve the right to alter this publication at any time.

COPYRIGHT, Peter Everard Ltd. 1993